A ship assembly production unit and method

Abstract

This invention provides a ship assembly production unit and method. The ship assembly production unit includes a conveyor roller conveyor, a welding robot, a vision recognition device, and a controller. The conveyor roller conveyor includes a feeding area, a lifting area, and a welding area. The welding area includes two welding positions, which can operate simultaneously, thus improving the utilization rate of the welding robot. Throughout the production process, the controller controls the production flow based on signal feedback, enabling automated equipment to complete key and complex processes, forming an intelligent single-piece flow mode. This ensures production efficiency and quality while reducing labor costs.

Description

Technical Field

[0001] This invention belongs to the field of shipbuilding technology, specifically relating to a ship assembly production unit and method. Background Technology

[0002] In shipbuilding, the most common component is the assembly of steel plate groups, typically composed of single-plate, single-ribbed or single-plate, multi-ribbed structures. This involves one or two ribbed plates vertically mounted on the base plate, with ribbed plate lengths usually ranging from 300mm to 4000mm and base plate lengths typically from 400mm to 4200mm. During installation, several issues arise: the steel plates are not perfectly straight; the plates are heavy, requiring multiple people to move or erect them; long welding lengths can lead to thermal deformation; and the installation process requires multiple people (making full automation or single-person operation impossible). Some shipyards have only designed some installation fixtures for this structure, achieving preliminary fixation of the base plate and ribbed plates. However, manual installation only involves partial fixation and spot welding, resulting in significant stress, poor quality, and cumbersome operations. Furthermore, traditional production lines rely on manual decision-making for processes and actions, demanding high levels of skill and effort from workers. Summary of the Invention

[0003] In view of the shortcomings of the prior art described above, the present invention provides a ship assembly production unit and method. The ship assembly production unit includes a conveyor roller conveyor, a welding robot, a vision recognition device, and a controller. The conveyor roller conveyor includes a feeding area, a lifting area, and a welding area. The welding area includes two welding positions, which can operate simultaneously, thereby improving the utilization rate of the welding robot. Throughout the production process, the controller controls the production flow based on signal feedback, enabling automated equipment to complete key and complex processes, forming an intelligent single-piece flow mode. This ensures production efficiency and quality while reducing labor costs.

[0004] To achieve the above and other related objectives, the present invention provides a ship assembly production unit, comprising:

[0005] The conveyor roller conveyor includes a loading area, a lifting area, and a welding area connected in sequence. The height of the welding area is lower than the height of the loading area. The assembled parts formed in the loading area are conveyed to the welding area through the lifting area. The welding area includes two identical welding positions connected in sequence. Each welding position includes a first roller conveyor, a second roller conveyor, and a lifting track. The projection surfaces of the first roller conveyor and the second roller conveyor overlap. The second roller conveyor rises or falls along the lifting track. When the second roller conveyor falls to the same plane as the first roller conveyor, the two are staggered.

[0006] A welding robot is positioned on one side of the welding area for welding the assembled components;

[0007] A visual recognition device, located at the end of the welding robot and in the welding area, is used to perform visual recognition on the assembled components;

[0008] The controller is communicatively connected to the conveyor roller conveyor and is used to control the opening and closing of the conveyor roller conveyor, as well as the rising and falling of the lifting area and the second roller conveyor; it is also communicatively connected to the vision recognition device and the welding robot and is used to control the welding robot to perform welding based on the image obtained by the vision recognition device.

[0009] Optionally, the conveyor roller conveyor is equipped with lifting devices at its first and last ends for loading and unloading materials, respectively.

[0010] Optionally, the conveyor rollers further include a back-burning zone and a feeding zone, the back-burning zone being located at the end of the first rollers and the feeding zone being connected to the back-burning zone.

[0011] Optionally, a back-burning device is provided below the roller conveyor of the back-burning zone.

[0012] Optionally, the welding robot is mounted on a base having slide rails for moving the welding robot between two welding positions.

[0013] Optionally, a position sensor is provided on the conveyor roller to acquire the position information of the assembled component and transmit the position information to the controller.

[0014] Optionally, a size sensor is provided on the second roller conveyor to acquire the size information of the assembled component and transmit the size information to the controller.

[0015] The present invention also provides a ship assembly production method, comprising the following steps:

[0016] Provide a ship assembly production unit as described in any one of the above statements;

[0017] The hoisting device is used to load materials, forming an assembly in the loading area;

[0018] The assembly component is transferred to the lifting area, the controller controls the lifting area to descend to connect with the welding area, and the assembly component is transferred to the welding position;

[0019] The controller controls the second roller conveyor to lift the assembly to the welding height, the vision recognition device performs visual recognition on the assembly, and the welding robot welds the assembly.

[0020] Once welding is complete, the controller controls the second roller conveyor to lower the assembled component to its initial position.

[0021] Optionally, forming the assembly in the feeding area includes:

[0022] Using the hoisting device, the base plate is first placed horizontally in the loading area, and then the stiffening plate is placed vertically to the base plate.

[0023] The base plate and the stiffening plate are assembled, positioned, and welded, and the weld seams are ground to form the assembly.

[0024] Optionally, the visual recognition device performs visual recognition on the assembled component, and the welding robot welds the assembled component, including:

[0025] The visual recognition device located in the welding area performs preliminary positioning of the assembled component, and the visual recognition device located at the end of the welding robot performs weld start point positioning;

[0026] The controller determines the welding process based on the size information and performs the welding.

[0027] Optionally, after welding is completed, the assembly is first transferred to the back-burning area for flame-burning, then transferred to the unloading area for manual grinding, and finally unloaded using the hoisting equipment.

[0028] Optionally, the two welding stations operate in parallel. While welding is being performed at one of the welding stations, at the other welding station, the second roller conveyor carries another assembly to the welding height, awaiting welding.

[0029] Optionally, the controller automatically controls the entire production process based on the position information obtained by the position sensor.

[0030] The ship assembly production unit and method provided by this invention have at least the following beneficial effects:

[0031] 1) The welding area includes two welding positions, which can operate simultaneously, thus improving the utilization rate of the welding robot;

[0032] 2) Throughout the production process, the controller controls the production flow based on signal feedback. The controller calculates and centrally controls the processing information, processing time, process arrangement, material transportation and other operations in the production process, forming an intelligent single-piece flow mode, which ensures production efficiency and quality and reduces labor costs.

[0033] 3) Lowering the height of the welding area, back-heating area and unloading area can prevent the assembled parts from interfering with the overhead cranes in the workshop during the manufacturing process, thus ensuring the safety of the production process. Attached Figure Description

[0034] Figure 1The diagram shown is a structural schematic of the ship assembly production unit provided in Embodiment 1.

[0035] Figure 2 The image shown is a top view of the ship assembly production unit provided in Embodiment 1.

[0036] Component designation explanation

[0037] 11. Feeding Area

[0038] 12 Lifting / Locking Area

[0039] 13 Welding Zone

[0040] 1301 First Welding Position

[0041] 1302 Second Welding Position

[0042] 131 First Roller Conveyor

[0043] 132 Second Roller Conveyor

[0044] 133 Guardrail

[0045] 100 lifting rails

[0046] 14 Backburn Area

[0047] 15. Material feeding area

[0048] 2. Lifting equipment

[0049] 31 Welding Robots

[0050] 32 bases

[0051] 4 Back-heating device Detailed Implementation

[0052] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0053] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention. Although the illustrations only show components related to the present invention and are not drawn according to the actual number, shape and size of the components, the shape, quantity, positional relationship and proportion of each component can be arbitrarily changed under the premise of realizing the technical solution of this invention, and the layout of the components may also be more complex.

[0054] Example 1

[0055] This embodiment provides a ship assembly production unit, including a conveyor roller, a welding robot, a vision recognition device, and a controller.

[0056] Combination Figure 1 and Figure 2 As shown, the conveyor roller conveyor includes a loading area 11, a lifting area 12, a welding area 13, a back-burning area 14, and a unloading area 15 connected in sequence. The height of the welding area 13 is lower than the height of the loading area 11. The assembled parts formed in the loading area 11 are conveyed to the welding area 13 through the lifting area 12.

[0057] like Figure 1 As shown, a hoisting device 2 is installed on one side of the loading area 11. Operators use the hoisting device 2 to lift the base plate and stiffening plates to the loading area 11, where they assemble, position, weld, and grind the weld seams to initially form the assembled components. In this embodiment, the hoisting device 2 is a cantilever-type assisted robotic arm, whose operating range covers the loading area 11. Operators can freely drag the assisted robotic arm to move it without remote control operation. The loading process is completed through the execution lifting device at its end. The execution lifting device can be designed as a magnetic suction type or a clamp type to ensure stability during the hoisting process. As an example, the hoisting device 2 is communicatively connected to a controller (not shown in the figure). The controller can calculate the load at the end of the hoisting device 2, thereby providing assistance for manual dragging.

[0058] like Figure 1 As shown, the lifting area 12 has a lifting track 100, and the conveyor rollers can move along the lifting track 100 between the height of the loading area 11 and the height of the welding area 13, thereby transferring the assembled component from the loading area 11 to the welding area 13. As an example, when the assembled component has not yet reached the lifting area 12, the lifting area 12 is at the same height as the conveyor rollers of the loading area 11. When the assembled component reaches the lifting area 12, the lifting area 12 descends to the same height as the conveyor rollers of the welding area 13, and transfers the assembled component to the welding area 13. Additionally, the lifting area 12 can also serve as a buffer area for the assembled component, capable of holding at least one large single-layer, single-rib type small assembled product.

[0059] Combination Figure 1 and Figure 2As shown, the welding area 13 includes two identical first welding positions 1301 and second welding positions 1302 connected sequentially. Each welding position includes a first roller conveyor 131, a second roller conveyor 132, and a lifting track 100. The projection surfaces of the first roller conveyor 131 and the second roller conveyor 132 overlap. The second roller conveyor 132 can rise or fall along the lifting track 100. When the second roller conveyor 132 falls to the same plane as the first roller conveyor 131, the two are staggered and merged into the same roller conveyor. As an example, when the assembly has not reached the welding position, the second roller conveyor 132 is at the same height as the first roller conveyor 131. When the assembly reaches the welding position, the second roller conveyor 132 carries the assembly to rise for welding. After welding is completed, the second roller conveyor 132 carries the assembly to fall and merges with the first roller conveyor 131 into the same roller conveyor for subsequent conveying.

[0060] As an example, a size sensor (not shown in the figure) is installed on the second roller conveyor. The size sensor is communicatively connected to a controller (not shown in the figure). At the start of welding, the size sensor is used to acquire the size information of the assembled parts and transmit the size information to the controller so that the controller can select a welding process that is suitable for it.

[0061] As an example, the second roller conveyor 132 can be raised at least 1.2m. When the first welding position 1301 is performing welding operations, the assembly can continue to be conveyed to the second welding position 1302 through the first roller conveyor 131 of the first welding position 1301, waiting for welding. This allows the feeding, discharging and welding processes to be carried out independently in space and time without affecting the conveying of other assembly components.

[0062] As an example, the height of the welding area 13 is lower than the height of the loading area 11. The height difference between the first roller conveyor 131 and the loading area 11 is between 0.5m and 1m. By reducing the height of the welding area 13, it is possible to avoid interference between the assembled parts and the overhead cranes in the workshop during the manufacturing process.

[0063] like Figure 2 As shown, the welding robot 31 is positioned on one side of the welding area 13 for welding assembled components. The welding robot 31 is mounted on a base 32, which has a slide rail parallel to the conveyor rollers for moving the welding robot 31 between the first welding position 1301 and the second welding position 1302. As an example, the welding robot 31 includes a robot-mounted welding machine and corresponding welding software and hardware, a weld seam positioning system, a torch cleaning and wire reduction system, etc., but these are not limited here.

[0064] As an example, a visual recognition device (not shown in the figure) is installed at the end of the welding robot 31 to track and adjust the welding position of the weld seam in real time during the welding process. In this embodiment, the visual recognition device can adapt to commonly used marine steel plate primer colors (including but not limited to gray, medium greenish-gray, yellow, red, blue, and purple) and is suitable for complex workshop environments, compatible with stains, handwriting marks, etc. on the steel plate. In addition, the visual recognition device (not shown in the figure) is also installed in the welding area 13, for example, it can be installed on the guardrail 133 of the welding area 13, to take overhead photos of the welding area 13 and the back-burning area 14 to obtain information such as the position of the assembled parts and the welding.

[0065] As an example, the controller (not shown in the figure) is communicatively connected to the vision recognition device (not shown in the figure) and the welding robot 31. During the welding process, the vision recognition device scans the assembly and transmits the scan information to the controller. The controller plans the welding path by processing the scan information and controls the welding robot 31 to perform correction and corner recognition during the welding process.

[0066] Combination Figure 1 and Figure 2 As shown, the back-burning zone 14 is located at the end of the first roller conveyor 131. A back-burning device 4 is installed below the roller conveyor of the back-burning zone 14. The back-burning device 4 is communicatively connected to the controller. The visual recognition device identifies the position and path coordinates to be back-burned and sends the information to the controller. The controller controls the back-burning device 4 to perform back-burning based on the information. As an example, the flame spray gun in the back-burning device 4 performs flame back-burning on the weld position below the stiffener through the gap of the roller conveyor. It can fine-tune the flame nozzle and the direction and position of the flame spray, and adjust the position of the stiffener to keep it always located below the stiffener. The back-burning device 4 can include two sets of flame spray guns to ensure that the assembled parts are thoroughly back-burned. The two sets of flame spray guns can be controlled independently.

[0067] like Figure 2 As shown, the unloading area 15 is connected to the back-burning area 14. A hoisting device 2 is also provided on one side of the unloading area 15. The operator uses the hoisting device 2 to complete the unloading process.

[0068] As an example, the controller (not shown in the figure) is used to collect and transmit signals, controlling and regulating the conveying process, manual workflow, equipment operation process, and visual recognition process in the production process. For example, the controller is communicatively connected to the conveyor rollers, which are equipped with position sensors (not shown in the figure) to acquire the position information of the assembled components and transmit the position information to the controller. The controller controls the opening and closing of the conveyor rollers based on the position information. The controller can also control the raising and lowering of the lifting area 12. When the position sensor (not shown in the figure) detects that the assembled component has arrived at the lifting area 12, the controller controls the lifting area 12 to descend. After the assembled component is transferred to the welding area 13, the controller controls the lifting area 12 to return to its original position, ensuring that no interference or collision occurs during operation. Similarly, the controller can also control the raising and lowering of the second roller 132. When the position sensor (not shown in the figure) detects that the assembled component has arrived at the welding area 13, the controller controls the second roller 132 to rise. After the welding of the assembled component is completed, the controller controls the second roller 132 to return to its original position.

[0069] Example 2

[0070] This embodiment provides a ship assembly production method, including the following steps:

[0071] Step S1: Provide the ship assembly production unit;

[0072] Combination Figure 1 and Figure 2 As shown, the ship assembly production unit described in Embodiment 1 is provided. Its specific structure can be referred to the description in Embodiment 1, and will not be repeated here.

[0073] Step S2: Use the hoisting device to load materials and form an assembly in the loading area;

[0074] First, the operator uses the hoisting device 2 to hoist the base plate and stiffening plate to the loading area 11 in sequence, placing them with the base plate at the bottom and the stiffening plate at the top. Next, the operator uses a magnetic triangular auxiliary assembly tool to place the stiffening plate on the installation position of the base plate to ensure the verticality of the stiffening plate assembly. Finally, the assembled sub-assemblies are positioned and welded, and the welds are ground to form the assembly.

[0075] Step S3: The assembly component is transferred to the lifting area, the controller controls the lifting area to descend to connect with the welding area, and the assembly component is transferred to the welding position;

[0076] As an example, when the assembly component is transferred to the lifting area 12, the position sensor (not shown in the figure) detects that the assembly component has arrived at the lifting area 12. The controller then controls the lifting area 12 to descend to the same height as the welding area 13. At this time, if the position sensor (not shown in the figure) detects that there is an empty space at the first welding position 1301 or the second welding position 1302, the assembly component is transferred to the welding area 13, and the controller controls the lifting area 12 to return to its original position. If the position sensor (not shown in the figure) detects that there is no empty space at the first welding position 1301 or the second welding position 1302, the assembly component is temporarily stored in the lifting area 12 and transferred after an empty space appears in the welding area 13.

[0077] Step S4: The controller controls the second roller conveyor to lift the assembly to the welding height, the vision recognition device performs visual recognition on the assembly, and the welding robot welds the assembly.

[0078] First, after the position sensor (not shown in the figure) detects that the assembly has reached the first welding position 1301, the controller controls the second roller conveyor 132 to lift the assembly to the welding height. Next, the vision recognition device (not shown in the figure) set in the welding area 13 takes a top-down view of the assembly to perform coarse positioning and weld start point positioning. Then, the size sensor (not shown in the figure) set on the second roller conveyor 132 acquires the size information of the assembly and transmits the size information to the controller, which selects a welding process that is suitable for it. Finally, the welding robot 31 arrives at the corresponding welding position to perform welding. During the welding process, the vision recognition device (not shown in the figure) set at the end of the welding robot 31 tracks and automatically corrects the weld, determines the weld end point and wraps the corner.

[0079] As an example, the first welding position 1301 and the second welding position 1302 operate in parallel. That is, while the welding operation is being performed at the first welding position 1301, another set of uprights is transferred to the second welding position 1302. The second roller conveyor 132 of the second welding position 1302 carries the other set of uprights up to the welding height. Similarly, a visual recognition device (not shown in the figure) takes a top-down view of the uprights to perform coarse positioning and weld start point positioning. A size sensor (not shown in the figure) acquires the size information of the uprights to match the corresponding welding process and wait for welding, thereby realizing cyclic welding between the two welding positions.

[0080] Step S5: Welding is completed, and the controller controls the second roller conveyor to lower the assembly to the initial position.

[0081] As an example, once welding is complete, the controller controls the second roller conveyor 132 to lower the assembled component to its initial position.

[0082] Next, the assembled component is transferred to the back-heating zone 14 for flame-heating. The back-heating device 4 heats the back of the weld seam of the assembled component to eliminate welding stress. As an example, after the position sensor (not shown in the figure) detects that the assembled component has arrived at the back-heating zone 14, the controller controls the back-heating device 4 to start the spray gun. After the position sensor detects that the assembled component has left the back-heating zone 14, the controller controls the back-heating device 4 to shut down the spray gun.

[0083] Next, the assembled component is transferred to the unloading area 15, where operators grind the welds and edges that need grinding. Finally, the assembled component is hoisted into the unloading frame by the hoisting device 2 to await logistics.

[0084] As an example, throughout the entire production process, the controller monitors and controls the production cycle of each workstation through signal feedback from position sensors, size sensors, and vision recognition devices. This ensures that transportation between the preceding and following processes only begins after the following process sends a completion signal; otherwise, transportation will not proceed even if the preceding process is completed, thus guaranteeing a single-piece flow production model. For instance, the assembled component will only be transferred to the lifting area 12 after detecting that the lifting area 12 and the loading area 11 are at the same height; the assembled component will only be transferred to the welding area 13 after detecting that there is an empty welding position; the controller will only issue a welding request after detecting that the welding robot 31 is idle; and the assembled component will only be transferred to the back-heating area 14 after detecting that it is idle.

[0085] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A ship assembly production unit, characterized in that, include: The conveyor roller conveyor includes a loading area, a lifting area, and a welding area connected in sequence. The height of the welding area is lower than the height of the loading area. The assembled parts formed in the loading area are conveyed to the welding area through the lifting area. The welding area includes two identical welding positions connected in sequence. Each welding position includes a first roller conveyor, a second roller conveyor, and a lifting track. The projection surfaces of the first roller conveyor and the second roller conveyor overlap. The second roller conveyor rises or falls along the lifting track. When the second roller conveyor falls to the same plane as the first roller conveyor, the two are staggered. A welding robot is positioned on one side of the welding area for welding the assembled components; A visual recognition device, located at the end of the welding robot and in the welding area, is used to perform visual recognition on the assembled components; The controller is communicatively connected to the conveyor roller conveyor and is used to control the opening and closing of the conveyor roller conveyor, as well as the rising and falling of the lifting area and the second roller conveyor; it is also communicatively connected to the vision recognition device and the welding robot and is used to control the welding robot to perform welding based on the image obtained by the vision recognition device.

2. The ship assembly production unit according to claim 1, characterized in that, The conveyor roller conveyor is equipped with hoisting devices at its beginning and end, which are used for loading and unloading materials, respectively.

3. The ship assembly production unit according to claim 1, characterized in that, The conveyor rollers also include a back-burning zone and a feeding zone. The back-burning zone is located at the end of the first rollers, and the feeding zone is connected to the back-burning zone.

4. The ship assembly production unit according to claim 3, characterized in that, A back-burning device is installed below the roller conveyor of the back-burning zone.

5. The ship assembly production unit according to claim 1, characterized in that, The welding robot is mounted on a base with slide rails for moving the welding robot between the two welding positions.

6. The ship assembly production unit according to claim 1, characterized in that, The conveyor roller is equipped with a position sensor to acquire the position information of the assembled component and transmit the position information to the controller.

7. The ship assembly production unit according to claim 1, characterized in that, The second roller conveyor is equipped with a size sensor to acquire the size information of the assembled component and transmit the size information to the controller.

8. A method for assembling and producing ships, characterized in that, Includes the following steps: Provide a ship assembly production unit as described in any one of claims 1 to 7; The material is loaded using a hoisting device, and assembled into components in the loading area; The assembly component is transferred to the lifting area, the controller controls the lifting area to descend to connect with the welding area, and the assembly component is transferred to the welding position; The controller controls the second roller conveyor to lift the assembly to the welding height, the vision recognition device performs visual recognition on the assembly, and the welding robot welds the assembly. Once welding is complete, the controller controls the second roller conveyor to lower the assembled component to its initial position.

9. The ship assembly production method according to claim 8, characterized in that, The assembly formed in the feeding area includes: Using a hoisting device, first place the base plate horizontally in the loading area, and then place the stiffening plate vertically to the base plate; The base plate and the stiffening plate are assembled, positioned, and welded, and the weld seams are ground to form the assembly.

10. The ship assembly production method according to claim 8, characterized in that, The visual recognition device performs visual recognition on the assembled component, and the welding robot welds the assembled component, including: The visual recognition device located in the welding area performs preliminary positioning of the assembled component, and the visual recognition device located at the end of the welding robot performs weld start point positioning; The controller determines the welding process based on the size information of the assembled components and then performs the welding.

11. The ship assembly production method according to claim 8, characterized in that, After welding is completed, the assembly is first transferred to the back-burning area for flame-burning, then transferred to the unloading area for manual grinding, and finally unloaded using the hoisting equipment.

12. The ship assembly production method according to claim 8, characterized in that, The two welding stations operate in parallel. While welding is being performed at one of the welding stations, at the other welding station, the second roller conveyor carries another assembly to the welding height, awaiting welding.

13. The ship assembly production method according to claim 8, characterized in that, The controller automatically controls the entire production process based on the position information of the assembled components obtained by the position sensor.

Images